Yarns, and processes and apparatus for producing the same



Mal-c114, 1958 J. w. HICKSQJR 2,825,199

YARNS, AND PROCESSES AND APPARATUS FOR PRODUCING THE SAME Filed Sepi. 16. 1954 2 Sheets-Sheet -1 30* INVENTOR.

- JOHN WILBUR HICKS,JR

ATTORNEY J. w. HICKS, JR

Match 4, H58 2,825,199"

'YARNS, AND PROCESSES AND APPARATUS FOR PRODUCING THE SAME A 2 Sheets-Sheet 2 Filed Sept. 16, 1954 INVENTOR.

JOHN WILBUR H|CKS,JR

mEC EZOKFOMJM ATTORNEY United States YARNS, AND PROCESES AND APPARATUS FOR PRODUCENG THE SAME John Wilbur Hicks, J12, Central, S. (1., assignor, by mesne assignments, to Deering Miiliken Research Corporation, near Pendleton, S. C., a corporation of Delaware Application September 16, 1954, Serial No. 456,419

24 Claims. (Cl. 57-36) This invention relates to improved yarns and more par ticularly the invention relates to yarns formed in part from filamentary material and in part from staple fiber material, and to novel processes and apparatus for producing the same.

The yarns in use today can be conveniently divided into two types, each having its own advantages and fields of use. One type of yarn in use today is spun from fibrous materials including animal fibers, vegetable fibers and synthetic staple fibers. Fabrics woven from such yarns have the advantages of high insulating value, good body, and Where desirable, lack of Sheerness. The spun yarns have the disadvantage of relatively low strength and, in addition, have disadvantages peculiar to the specific type of fiber or fibers employed in their formation. For example, spun yarns made of animal fibers, such as wool, lack washability while yarns formed of the vegetable fibers, which unlike wool are fully Washable, lack the body, insulating value, and richness of woolens, and are characterized by poor crease retention, low wrinkle resistance and high moisture absorption. Yarns spun from synthetic fibers, which in many instances have good crease retention, high wrinkle resistance, low water absorption, and are fully Washable, sufier one or more of the disadvantages of being cold to the touch, of low tensile strength, tending to collect static electrical charges, or the disadvantage of tending to pill badly when woven into fabrics.

The continuous filament yarns are widely employed in instances where sheerness is not objectionable or is desired while the continuous filament yarns have the advantage of greater strength, they have the disadvantage of resulting in fabrics with low heat insulating values, the disadvantage in most instances of collecting static electrical charges, and the disadvantage of being unsuitable for the preparation of fabrics with the opaqueness and body desirable for suiting materials and the like.

At least one attempt has been made to prepare a yarn having the advantages of both the filamentary yarns and the staple yarns by using a strand of filamentary yarn as a core and encircling it with a helix of spun y-arn. Such yarns have, however, met with no degree of commercial 7 success for the reason that when an attempt is made to weave the yarn, the helix of spun yarn is distorted until a knot is formed thereby breaking the strand of spun yarn and allowing it to he slid along the length of the filamentary core exposing the bare core for a length until the condition is noticed by the operator and the machine handling the yarn brought to a stop.

According to this invention there are provided yarns, composed in part of filamentary materials and in part of staple fiber materials, which overcome the difficulties experienced with the core type yarns described above and which enable one to achieve the advantages of both the spun yarns and the filamentary yarns with few if any yarns are generally employed.

Patented Mar. 4,1958

among the individual filaments. The fibrous material may be evenly distributed along the length of the filamentary strand, in which case one has a yarn suitable for use in instances where spun yarns are generally employed, or the fibrous material may be spaced along the length of the filamentary strand in the form of distinct assemblages of fibers, in which case there results a novelty slubbed yarn with many advantages over prior art slubbed yarns and suitable for use in instances where the filamentary inasmuch as yarns having the fibrous material evenly distributed along the length of the filamentary strand and yarns having the fibrous material collected into distinct assemblages of fibers are so completely difierent in appearances and utility, the two types of yarns, as well as the apparatus for preparing the same, will be independently discussed in subsequent paragraphs.

With rererence to yarns wherein the fibrous material is evenly distributed along the length of the filamentary strand, the new yarns of this invention have many surprising advantages over the conventional spun yarns. It is believed that the potentialities of the new yarns can best be illustrated by comparing a yarn according to this invention comprising continuous strands of polyester filaments and having wool fibers intertwined there between,

with a conventional spun yarn composed of a mixture of wool and polyester fibers. Blends of wool fibers and polyester fibers have been enthusiastically received by the public in recent years because of the excellent crease and shape retention of fabrics woven therefrom even when wetted and because of their excellent wrinkle resistance and superior strength as compared to pure woolens. However, fabrics woven trom such yarns, due to the presence of polester fibers, tend to pill badly and to collect static electrical charges. Yarns prepared according to this invention from polyester filaments and wool fibers, when woven into cloth, do not pill because the polyester material is present only in the form of embedded filaments rather than in the form of exposed surface-fibers, nor do they collect static electricity to the same extent as fabrics Woven from spun blends of polyester fibers since when a fabric woven from the new yarns of this invention is brought into contact with another surface or with itself, the contact is almost entirely limited to the Wool fibers which extend from the embedded polypster filaments. In addition, fabrics woven from yarns according to this invention display substantially the same crease retention and wrinkle resistance as do fabrics woven from conventional blends and display increased dimensional stability because the wool fibers are locked in position by the polyester filaments and cannot migrate. Fabrics woven from the new yarns are also characterized by greater strength because the polyester component of the yarn is present in the form of filaments rather than in the form of staple fibers.

In view of the above comparison, it will be seen that the components of the new yarns of this invention can be selected to result in fabrics having the advantages de sired in any particular instance. For example, fabrics can be Woven having the appearance of cotton and substantially the strength of nylon by employing yarns according to this invention composed of nylon filaments and cotton fibers. In addition, the fabric will have a lower water absorption, better crease retention, and increased dimensional stability. The new yarns of this invention result in more satisfactory fabrics even when the fibers and filaments are of the same chemical composition as compared to fabrics Woven from yarns containing staple fiber material. For example, a fabric woven of 100% polyester material according to this invention generally displays a decreased tendency to pill and in ad presence of filamentary strands.

Yarns according to this invention wherein the fibrous material is collected in distinctassemblages to result in 'a; slubbed filamentary yarn" have numerous advantages o'ver "priora'rt slubbed yarns, are more readily prepared thanslubbed filamentary yarns of the prior art and are "as readily'prepared as prior art 'slubbed' staple yarns. fSlubbed' staple yarns can be prepared by momentarily and rapidly changing the drafting rate on annodified "spinning frame, so that segments of the finished strand aredrafted to a'lesser degree than sections of the strand 'on either side thereof, but such a method cannot be em- "ploy'ed for th'e'pro'duction of slubbed filamentary yarns. fieretofoi'elit has been generally necessary in order to produce asatis'facto'ry slubbed filamentary yarn to'resort tdv'arying the denier 'of the "individual filtiment'sin the original'ext'ruding' process and the limitations and disadvantages of such a method will be readily"ap1;1arent.

"Nevertheless, there have been'limite'd quantities ojf 'slubbed "ditioii is"'ch"ai'at:terized' by "greater strength because of the filamentary yarns made by such a'process sineelslubbed spun yarns cannot'be employed for theweaving or knitting of sheer"fabrics and since 'thefilar'n'enta'ry yarns 'are considera'bly stronger than the'spun' yarns.

' The new slubbed yarns of this invention have'niimerous advantages over bothprior art filamentary slubbed yarns needs whereas he has been previously required to place his order long in 'advance'for specially' extruded yarns.

A further advantage is that thenew' yarns of this invention can be produced in a very wide" range of deniers with many different types and sizes of slubs. With reference to prior art staple slubbed yarns, the new yarns of a surface charge under favorable conditions for a period of' about one second or longer are satisfactory and are referred to in this specification and claims as substantially non-conductive. Practically all non-metallic filamentary yarns fall within this classification unless, of course, they have had their surfaces coated with a material to render them conductive and illustrative examples of filamentary yarns which can be employed in the new process of this invention are nylon, polyester yarnssuch as sold under the name of Dacron, polyacrylic yarns such as those sold under the names of Orlon and Acrilan," viscose rayon yarns, cellulose acetate yarns, silk, glass yarns, and synthetic protein yarns.

It is well known in mean that many m'ulti filament yarns when received from the manufacturer are coated with an anti-static agent which serves to lend surface conductivity and to prevent the yarns from holding a strong electric charge. .In some instances. these anti- 'static agents areso effective as to cause difficulty in the (20 new process of this. invention although such difficulties can, in most instances; be eliminatedflby operating in an atmosphere with a very low relative humidity. Most of .the commonly employed anti-static agents depend,;at least "partially, upon their hygroscopic nature to lend conduc- 25 very low relative humidity, the effectiveness of the antistaticiagent is temporarily destroyed. Such a procedure,

tivity so that if one operates in an atmosphere with a if it gives satisfactory results, is generally preferable to removal of the anti-static agent since after, the operation is'complet'ed, the anti-static agent, again becomes effective and the need for a second application is eliminated. Of course, if difiiculty is encountered even when operating in a dryatmosph'ere, it is generally advantageous "to completely remove the anti-static agent by scouring or thisinvention offer the advantage of greater" strength as well as the advantage of being suitable for usein the weaving of sheer fabrics.

A"further"advantage 'of the newslubbed yarns of this invention over both prior art stapleslubbed yarns and prior'art filamentaryslub'bed yarns is that the filaments able choice of materials it'is'possible reproduce yarns of novelty fabrics.

novel process for preparing nevr yarns of either of theabovc described types has been'discovered and it lstntended that this'process also constitute a part'of the invention. According to this new processa strand con-' -ta1ning aplurality of filaments hasanelectric charge imparted thereto, preferably by beingj'brought into'intimate other knownte'chniques.

Since it is necessary for the individual filaments of the" filamentary strand to be separated to permit insertion 'of'the staple fiber material; a strandhavin'gas little twist as possible should be employed. When preparing yarns accordingto this.invention having staple fiber material spread evenly along the length thereof, best results are obtained'using a filamentary strand having zero, twist since evena small degree of twist will generally'result in "wherein the'filaments can be dyed 'IeaVing the sl'ubs undyed, theslubs'can'be dyedleaving thefilantents'undyed, h o'r'snch'thatthe' filaments andslubs can both bedyed in -a'. "single' bath butin"diifere'nt colors'onshadesf This greatlyincreases the utility of the yarn in the preparation contact with a dissimilar material, so thatthe filaments become separated one from the'other due to mutual repulsion. A section of the-strand wherein thefilaments are-separated one from the otheris thembrought into contact with either an intermittent or continuous supply 1 of'fibrous material and the strand is*thereafter"twisted r to entwine'onentangle the fiberstherein.

It is afcature of the new process that it can be em- :be-apparent that it will be necess'ary for the surface of a the filaments to have a conductivity su'chthat: a charge "can be held for'the fraction of a secondnecessary for' -the filaments to become separated one from thetother and for the fibrous material to bebrought into contact with the separated filaments. Yarns capable: of holding:

of the slub.

there being segments where no fibers are inserted. When only necessary that there be employed a filamentary strand with 'aisufiiciently low twistto readily allow separation offthe filaments for a length considerablyinexcess' of that mother words, if it is desired that the slubbe one inch long, the filamentary strand jshould notbe-solhighly twisted thatltbe twist cannotreadily be "forced backialong thejlength of ,thestrandfasufiicient dista'nceto allow the individual filaments thereof to be separated for 'this length without appreciable force being applied." It has been foundto be advantageous to employ filamentary strands having not'n'torethan about 'one turn per inch of twist and preferably notlrnore than about onehalfturn per inch of. twist when producing slubbed yarns and strands'having agreater'amount of twist may ad- 'vantageously'be'untwistedito the point that they have not more than about /2 turn per inch of twist so that the slub may be more (readily inserted.

The staple fiber material'is most conveniently supplied in the form of sliver, roving, or the like which can be readily drafted to spread and separate'the fiber for introduction into the filamentary strand. When. preparing slubbed yarns according to this. invention, the fibers of'staple lengthma'y be broken from a continuous filamental-y. strand at the time of insertion but this results in the fibersbeing allof substantially thesame length and alignment so thatthe resulting slub does not'blend smoothly into the yarn. It'is, therefore, generally advantageous,

' even when preparing slubbed yarns, t o employJmaterial t which has been-previously cut toistaplelength or which naturally occurs in this form.

The new process is operative independently of the electrical characteristics of the fibrous material and it is only the electrical properties of the filamentary material that are of prime importance. The fibrous material may have a conducting or a non-conducting surface and if the fibers are non-conducting they may be adjacent to, identical with, or widely separated from the filamentary material in the triboelectric series. This is because the fibers are secured in position by being entwisted among the filaments of the continuous strand and the success of the new process is not dependent upon there being any electrostatic attraction between the fibers and the filaments of the continuous strand.

The staple fiber material may suitably be of substantially any chemical composition and may be composed of such materials as glass, bronze or other metals, proteinaceaus materials such as wool, cellulosic materials such as cotton, flax, viscose rayon or acetate rayon, synthetic polymeric materials such as nylon, polyester fibers, acrylic fibers or other vinyl fibers. Cotton fibers entwined in glycol terephthalate polyester or viscose rayon filaments, wool fibers in nylon, polyester or acrylic fila ments and staple length silk fibers in glycol terephthalate polyester filaments are illustrative examples of combinations which produce interesting yarns.

If the electrical charge is to be imparted by the preferred means of bringing the filamentary strand into con tact with a different material, the dissimilar material can be practically anything which presents a solid, non-adhesive surface that is not unduly abraded by contact, and the term solid is here used in a loose sense to include such materials as glass and certain resins which are sometimes called super cooled liquids. Specific examples of suitable materials include amber, hard rubber or other resinous materials derived in whole or in part from natural sources, phenol-formaldehyde, polystyrene, nylon, or other synthetic resinous materials, ceramic or vitreous materials such as baked clay and glass, Wood or other fibrous materials, and steel, bronze or other metals. While the charge can be created by simply bringing the two dissimilar materials into intimate contact with each other, as a general rule better results are obtained if there is frictional movement between the two dissimilar materials. Better results are also obtained if the material with which the filamentary strand is to be contacted or against which the filamentary material is to be rubbed is as far removed from the strand in the triboelectric series as possible and since the polarity of the charge imparted to the strand is not material, as far as the operativeness of the process is concerned, the substance with which the strand is to be contacted for producing the electric charge may be on either side of the strand in the triboelectric series. Specific examples of advantageous combinations are a hard rubber or phenol-formaldehyde resin surface for strands of nylon, glass, silk or viscose rayon, and a glass surface for strands of acetate rayon or acrylic filaments such as sold under the name Orlon.

While it is only necessary that the new yarns of this invention contain a plurality of filaments between which the staple fiber material is entwisted, the filamentary strand from which the yarns are prepared should preferably contain at least about ten filaments since if the number of filaments is below this figure, the staple material may not be adequately secured in position. [in other advantage of employing filamentary strands containing at least about filaments is that they are more readily available and generally are less expensive than strands with a smaller number of filaments. There is no upper limit as to the number of filaments that the filamentary strand may contain except that imposed by availability. In some instances two readily available strands of lower denier than desired may be run together to give a single strand and thereby increase the total number of filaments and, in fact, this procedure has the additional advantage, for preparing yarns with staple distributed as evenly and as continuously as possible along the length thereof, that any turns of incidental twist originally present in one of the lower denier strands or twist resulting from the strand being withdrawn from the package, will not coincide with the incidental twist in the second lower denier strand so that the completed yarn is more uniform.

The ratio of fibrous material to filamentary material may vary within wide limits and depends to some extent upon the intended use of the yarn. If one is not interested in producing yarns which have the general appearance of spun yarns and is interested only in obtaining a novel appearance such as can be obtained with slubbed yarns, the percentage of fibrous material may be as low as a fraction of one percent, but if it is desired that the yarn have the general appearance of a spun yarn, best results are generally obtained from combinations wherein the staple fibers constitute from about 30 to 86 percent by weight of the yarn. The appearance of yarn according to this invention wherein the staple fiber material is envenly distributed and wherein the staple constitutes about 40% or more of the total weight, is almost identical to that of a spun yarn except that it is generally more uniform and the long fiber protrusion or fuzziness is generally somewhat less. In most instances it is not advantageous to employ the staple material in percentages greater than about 8$% since this requires the insertion of a greater amount of twist and since the yarns begin to lose some of the advantageous characteristics imparted by the filamentary strands. There are exceptions, however, and one instance when it may be desirable to exceed this figure is in the preparation of yarns for very light weight summer materials wherein the filamentary material, even though present in very small percentages, can serve to increase appreciably the minimum breaking strength. This makes possible the production of extremely light weight fabrics and one can,

. for example, weave a fabric which approximates in appearances and strength a good tropical woolen but which has only about one-half the weight.

The amount of additional twist that should be inserted in the filamentary strand following its contact with a suitable source of staple fibers to more adequately secure the fibrous material in position should be at least about 5 turns per inch and preferably at least about 10 turns per inch. This additional twist forces the filaments of the strand together, even though they might still retain the remnants of the static charge earlier imparted, and thus secures the fibers firmly in position so that they. are not readily dislodged. There is no upper limit as to the amount of twist that can be inserted, as far as the operativeness of the new process is concerned, since the greater the amount of twist, the more rigid the securement of the fibers; however, excessive twist in the new yarns of this invention will, as in any other yarn, result in bad handling characteristics.

While the new process can be performed by hand, novel apparatus for more eificiently performing the same has been invented and it is intended that such apparatus also constitute a part of the present invention. The new apparatus comprises a means for imparting an electric charge to the filamentary strand, preferably in the form of a rotating member adapted to rotate in contact with the strand, means for bringing the strand, with its filaments widely separately, into contact with a supply of fibers, and means to thereafter twist the strand so that the fibers become entwisted among the individual filaments thereof. The last-named means can take the form of a conventional spinning spindle with ring and traveller while the means for bringing the strand into contact with the assemblage of fibers preferably takes the form of a drafting frame adapted to pass the filamentary material through only the last pair of elements.

Two preferred embodiments of apparatus for prepar- -.ingzthenew yarnsaof this invention will now-she described withjreferencetothe accompanieddrawings inwhich: '1; "Figure 1 is-a; schematic view in perspective; with prin- "cipal parts in location, of an arrangement suitable for preparing yarns having staple fiber material spread evenly along their length.

, Figure 2 is a crosssection takensubstantially about .the line 2-2 in. Figure 1.

Figure 3 is a schematic viewin perspective, with principle part in location, of a modified form of the paratus illustrated in Figure l andsuitable for use in the preparation of either slubbed, yarns or yarns having staple fiber material spaced evenly along the length of the yarn.

Figure 4 is across sectional vicw taken substantictily along the line,4-4 inFigure 3.

10 so that a yarn end or strand 13 may be readily unt With reference to the drawings in greater, detail and =52-ofstaplefiber material which maysuitablybe in the .form of a bobbin, cop, spool or the like, The staple fibermaterial, preferably in the form of sliveror roving,

with particular reference to Figures 1 and 2 of the drawings, the reference numeral 16 indicatesa yarn supply package such as a cone hank, cop orthe like, of multifilament yarn of a type capableof being given a static A pigtail guide, indicated by thereference charge. numeral 12, is positioned over the yarn supply package wound therefrom without tangling. Immediately below the pigtail guide 12 is a tension array indicated by the reference numeral 14 and comprising a pair of disk tension devices between which the yarn is adaptedto be passed so that it can be placed under tension in the section of the yarn path immediately thereafter.

There is generally indicated by thereference numeral -is. passed from the supply 52 to the back rolls of drafting frame 32 in a conventional manner.

From what has been said it will be apparent that an apparatus such as above described can readily be constructed from; a conventional spinning frame by simply v, sack between the delivery roll pair to pigtail guide 40 2O andyspindle array 42. An end of sliver or the like is passed from supply 52 to the rear elements of drafting frame 32 where it is adapted to be passed through the drafting frame in a conventional manner.

Motor 24 is then-placed in operation to result in frictional contact of the blades 28 and 30 with the yarn end 13 and spinning array 42 and drafting frame 32 are then placed in operation.

As. strand 13 travels about the electrifying array 16 it is alternately placed under tension and relaxed due to 16 an electrifying assembly for imparting a static charge to the yarn end 13. The assembly 16 comprises a shaft 18, rotatably supported at either end byanti-friction bearings, indicated by the reference numerals 2t) and 22, t which is adapted to be rapidly rotated by means of an electric motor 24 acting through a drive shaft 26. Inset position-of strand 13 in the triboelectric series.

- Positioned rearwardly of assembly '16 is a three-ele- The protruding blades 28 the rotation of shaft 18 and the eccentric protrusion of blades, 28 and 30. At the same time thefilam-ents in strand 13 become electrified by frictional contact with blades 28 and 3t) and this makes them mutually repulsive. During the periods when strand 13 is in a slackened con- U dition, the filaments become separated due to their mutual 'll'lCIliI drafting frame generally indicated by reference numeral 32 and having a back roll pair 34, an intermediate pair of elements 36 and a delivery pair 33. drafting frame 32 may be and preferably is of the type generally found on a conventional spinning frame and while the intermediate elements have been illustrated for convenience as comprising only a pair of .rolls, it will be u understood that a long-draft frame, wherein the intermediate elements comprise a pair of traction belts or the like may suitably be employed. In this embodiment of the invention the drafting frame is driven in a conventional manner so that the three elementsare geared together and the intermediate elements and delivery rolls spinning or twisting array generally indicated by the reference numeral 42. The array 42 comprises a bobbin 44 adapted to be rotated in a conventional manner and i to: collect a supply of yarn indicated by the reference numeral 46.. The array also comprises a. conventional t The spinning ring 48 carrying a traveller Stladapted to rotate about the bobbin 44 in a conventional. manner. as the yarn is twisted andwound on the. bobbin.

Located rearwardlyiof drafting frame .32 isa supply 1.

repulsion and enter between delivery rolls 38 in spaced relationship to each other. The end of roving or sliver 53 also enters between delivery roll pair 38 in a spread and ribboned condition due to its being drafted between the back roll pair andthe intermediate elements of the drafting frame 32 and as the opened band of fibers contacts the separated filaments of strand 13,. the fibers tend to be partially forced between the filaments by the pressure of the delivery roll pair 33. On departing delivery roll pair 38, the filamentary strand is immediately twisted to entwinc or entwistthe staple material among and be tween the filaments and to thereby lock the same in position.

With reference to Figures 3 and 4 of .thetdrawings, the reference numeral 60 indicates a, yarn supply package such as a cone, hank, cop or the like, of multi-filarnent yarn ofa type capable of being given a static charge. A pigtail guide, indicated by the reference numeral 62, is positioned over the yarn supply package 60 so that a yarn end or strand 63 may be readily unwound therefrom and immediately below the guide 62 is a tension array, indicated by the reference numeral 64, com-prising a pair of disk tension devices between which the strand 63 is adapted to bepassed so that it can be placed under tension in the section of the yarn path immediately thereafter.

Inasmuch as the present process requires that a static charge be imparted to the multi-filament yarn, and since such yarns are more inclined to take a static charge when they are in a dry state, this embodiment of the invention is illustrated as being provided with means for drying .tconductorsfid to a supplyof electric pow er. So that the air distributed by header 68 will be at higher than room temperature and thereby capable of exerting a greater drying effect, a section 76 of the conduit connecting fan 66 with header 63 ispreferably provided with heating elements such as the resistance elements indicated by the reference numeral 78. The resistance elements 78 are connected to a suitable power supply by electrical conductors indicated by the reference numeral 80. A single switch 82 can be employed for operation of both the electric motor 72 and the heating elements 78.

The tube 70 is illustrated as being positioned in the yarn path immediately below and forwardly of tension array 64 and is adapted to receive yarn end 63 through an orifice 84 in header 68. To avoid the use of a threading tool, tube 70 and header 68 may be provided with a narrow slit as indicated at 86 so that the yarn end may simply be pulled into its proper flowpath.

There is generally indicated by the reference numeral 88 an electrifying assembly for imparting a static charge to the multi-filament yarn. a shaft 90 which is adapted to be rapidly rotated by any suitable means such as an electric motor 92. Inset in a suitable groove in shaft 90 and extending longitudinally along a portion of its length is a rubbing element or blade 94 adapted to frictionally contact the yarn end 63 and impart'a static charge thereto. As previously explained, blade 94 is preferably of a material widely separated from the com-position of strand 63 in the triboelectric series.

So that the multi-filament yarn 63 will be contacted by the blade 94 only when desired, there is preferably provided a movable arcuate shield indicated by the reference numeral 96. The arcuate shield 96 is mounted for rotation about the axis of shaft 90 so that it may be pivoted to a position such that it will hold the yarn end 63 out of contact with blade 94 or to a position such that it will be completely out of contact with the yarn end as is clearly illustrated in Figure 4.

Positioned rearwardly of assembly 88 is a three-element drafting frame, generally indicated by the reference numeral 98, having a back roll pair 100, an intermediate roll pair 102 and a delivery roll pair 164. The drafting frame 98 maybe and preferably is of the type generally found on a conventional spinning frame except that in this embodiment of the invention, the delivery roll pair is driven independently of the other elements of the drafting frame. In Figure 3 means for driving the delivery roll pair 104 is illustrated as comprising a shaft 106 and an electric motor 108. The electric motor is illustrated as directly driving shaft 106 but it will be appreciated that Figure 3 is only schematic and that an appropriate gear train for reducing the rate of rotation of delivery rolls 104 to a suitable value should be provided. Electric motors 108 and 92 may be connected, in parallel through electrical conductors 110 and 112 and operated through a single switch 114 since it is desirable that the .two motors be in operation at all times when the apparatus is being utilized.

, 'The back and intermediate roll pairs 1% and 102 of drafting frame 98 are adapted to be employed for either the insertion of a slub of fibers into the m'ulti-filament strand 63 or for the feeding of a continuous supply of fibrous material to the strand 63 as it is led from the as sembly 88 over the top roll of roll pair 104 and back between the two rolls. The fibrous material is preferably supplied in the form of staple sliver or roving, a suitable supply of which is indicated by the reference nu meral 116 in the form of a bobbin, cop or the like. An

. end 118 from supply 116 is illustrated in the drawings as production of slubbe-d yarns the operation of these ele- The assembly 83 comprises 4.

ments must be intermittent and in Figure 3 the driving means is illustrated as comprising a rotatable shaft 120 extending from back roll pair to an electric motor 122. it will again be understood that although the connection in Figure 3 of the drawings is illustrated as being direct, suitable reduction gears should be provided so that roll pair 100 is driven at an appropriate speed. Roll pair 102 is driven from shaft by gear 124, idler gear 126, gear 128 and shaft 130. As in conventional operation the roll pair 102 should be driven at a higher rate of speed than roll pair 100 so that there is drafting of the strand 118 between the two roll pairs.

Located forwardly of drafting frame 98 is a pigtail guide 132 which is adapated to receive the yarn end 63 following its departure from roll pair 104. Positioned immediately below the gmide 132 is a conventional spinning or twisting spindle array generally indicated by the reference numeral 134 and comprising a spindle 136 over which there is placed a bobbin 138 adapted to collect a supply of yarn 146. A conventional spinning ring 142 with a rotating traveller 144 also constitutes a part of the array 134. The spindle 136 is adapted to be driven in a conventional manner by contact of a whorl section 146 with a belt 147 running about a pulley 143 which is illustrated as being driven by motor 108 through a gear 149 on shaft 106, gears 150 and 151 on shaft 152, gears 153 and 154 on shaft 155 and a gear 156 on a shaft 157 carrying pulley 146. It should be clear, however that it is not intended that the drawing necessarily illustrate the actual gear arrangement for driving spindle array 134 but only that front roll pair 104 of drafting frame 98 and the spinning array 134 can be and preferably are driven by a common power source.

The reference numeral 158 indicates a source of electrical impulses, preferably random in frequency, and can suitably be a device of the type described in U. S. Patent No. 2,622,282, or any other arrangement for supplying pulses of electrical energy of controlled duration. The pulses from source 158 are fed in one instance through conductors 160 to a solenoid 162 with a core 164 of conventional design and construction. The core 164 is connected through a flexible strand or cord 166 to a spring member 168 having one end secured to a suitable support. The flexible cord 166 between core 164 and spring 166 is wrapped one or more turns about a cylindrical member 170 which is positioned on the extended axis of rotation of shaft 90 and operatively connected through an arm 172 to shield 96. The cord 166 is of such length that spring means 163 normally retains core 164 partially removed from solenoid 162 when the solenoid is not energized and the positional relationship of member 176 to strand 166 is such that when the solenoid 162 is not energized, shield 96 is in a position such that contact of strand 63 with blade 94 is prevented. When solenoid 162 is energized, core 164 is moved against the bias of spring 168 thereby rotating shield 96 to permit contact of the strand 63 with the blade member 94.

The electrical pulses from source 158 are also transmitted through a conductor 174 to an electric time delay device indicated by the reference numeral 176. Electric time delay devices suitable for use in the apparatus of this invention are commercially available from several sources and the exact construction of the unit is not intended to constitute a part of the present invention. Excellent results have been obtained with a General Electric Electronic Time Delay Relay. The device is adapted to be activated by the impulse received through conductors 174 and a selected time later, sufiicient to allow passage of a point on strand 63 from assembly 88 to the delivery roll pair 104 of drafting frame 98, to send an electrical impulse through conductors 178 to motor 122. The electronic time delay device is preferably so adjusted that the delayed impulse sent to motor 122 terminates simultaneously with the impulse sent to solenoid 162 through conductors 160.

. aaaa apparatus accordingto this ,embodime'ntpf theinvention From-what has been saidv it wilhbe; apparent that an andribboning is ,obtained between roll pair. 19 2 and roll pair 104. The drafting and ribboning of strend 118 can also be Constructed froma conventional spinning frame by simply addingthe assembly 88, the strand drying arrangement comprising fan 66 and header68, and

tension array 64. The spinning frame need then only be modified by disconnecting the back two I011 ,pai rs of the drafting frame, with, which the spinning frame is. provided, from their conventional driving means while allowing the front roll pair to continue to be driven in a conventional mannerby the motor which drives the spinning spindle.

A separate motor activated through a v source of electrical impulses and; an electronic time delay is then provided for driving the back elements of the paeakge 60 .is threadedthrough guide 62, ,tension array 64, and then is pulled through slit 86 into tube 7 0 The yarn end is then passed around assembly 88, over and between the delivery roll pair 104 of drafting, frame 98 and thereafter through guide 132 to the spindle array 134.

A second. strand preferably formed, from staple fiber. materials is led frompackage 116 between the back roll 1 pair 100 and center. roll pair 102 of drafting frame 98.

The apparatus is now readyfor operation and switch 82 can be thrown to place the fan 66in operation and heat the resistance elements 78. After a few moments to allow L the resistance elements to become heated and the segthe source of electrical impulses 158 and theelectromc ment of strand 63 in tube 70 to become thoroughly dried, switch 114 can be thrown to place motors 108 and 92 in operation and the source of electrical impulses 158 94 and strand 63 results in the filaments of strand 63 in each instance acquiring a like charge so that they exhibit a mutual repulsion of each other and tendto become as greatly separated as possible.

during its passage through drafting frame 98isirnpprtant since this permits a smoother blending ofthe fibers into strand 63 and permits the fibers to become more thoroughly ensnared between the individual filaments of strand 63 as it departs delivery rolls 104 and is twisted by spindle array 134.

After a suitable preselected interval of time the electrical impulse furnished by source 158 is terrni nated. One result of the termination of the impulse from source 158 is that core 164 is drawn upwardly, frornsolenoigl 162 by the resiliency of spring 168 which in turn results in the rotationof member 170 and thepositioning of shield 96 .so that strand 63 is no longer in contact with blade 94.

This allows the twist which has accumulated above assembly 88 to pass and thereafter become evenly Qistributed in strand 63 in its journey .to spinningarray 134. The termination of the impulse from source 158 als o results in the de-energizationof motor122 and the inactivation of roll pair 100 and roll pair 102. Since roll pair 104 continues to operate, strand 118 is ruptured between roll pair 104 and roll pair 102 and the trailing endis bound into strand 63. This completes the cyele and the ap paratus continues to function only asa twisting ff rame nntil at some future time another electrical impulse is provided by source 158.

For theproduction of yarns havingstaple length fibers spaced evenly along the length of the filamentary strand, the apparatus illustrated in Figures 3 and 4 pt the drawings is operated exactly as described above except that time delay 176 are set or shunted to provide a continuous supply of energy to the solenoid 162 and to mot o r 122. Continuous operation of the motor 122 results in the back elements of drafting frame 98 feedingan even Blade 94 and shaft also contribute to the success- 1 ful operation of the new apparatus -in several other re- In the first place, the blade rotating in a -direcspects. tion opposed to the forward movement '.of the strand 63, tends to holdback the twist and also to exert a rihboning effect so that the filaments of strand 63 are encouraged.

to enter the bite of delivery rolls 104-in spaced parallel relationship. In addition, the eccentric protrusion of blade 94 from shaft 90 acts to alternately tension and and continuous supply of staple fibers to ,beentwisted in strand 63 while continuous energizationof solenoid 162 results in shield 96 being retained in an; inoperative position at all times so that strand 63 is uniformly eleetrified as it is fed to the delivery. rolls 104 of d raftingfrarne 98. Having thus described my invention what I desire to claim and secure by Letters Patent is:

1. A method for preparing novelty yarns whichacomprises imparting an electrical charge to. a filamentary strand, containing a plurality of ,filarnents,;along at. least a portion of its length, whereby the'filaments are rendered mutually repulsive and become separated one from the relax end 63. The periods of relaxation permit the filasource 158 reaches time delay 176, the impulse is trans;

mitted to motor 122 which places in operation the back two elements of drafting frame 98. The rotation of these rolls feeds strand 118 to the bite of roll pair 104 Where it is pressed into contact with the separated fila- 1 merits of strand 63 andbecomes entwined among the filaments of the strand as it departs delivery rolls 104 and is twisted by spindle array 134. .lnasmuchas the rolls in pair 102-are rotating at a higher rate than the. rolls in roll pair 100, it will be seen that strand 118 is.

drafted-so that-the fibers therein; are spread and ribboned in a conventional manner. be operated at a higher rate th an either of the. back elements of the drafting framepo that, further drafting If desired, roll pair 104 can other, contacting the separated filaments, with a supply of .staple length fibrous material, andtthet'eafter tpiisting the strand to entwine the fibrous material between said filaments.

2. A method according to claim-l wherein the amount of twist imparted to said filamentary strandafter its contact with said supply of staple length fihrousmaterial is at least about five turns per inch.

3. A method according to claim 2.wherei n said filamentary strand prior to its contact with said supply of fibrous material has substantially zero turns ofltwi st per inch and said supply of fibrous material is continuous, whereby a yarn is produced having staple length material distributed substantially evenly alongits length.

4. .A method for preparing a novelty yarn havipg the appearances of a spun yarn which comprises b ringing filaments of said strand into contact with a eontinuous supply of staple fiber material, and thereafter imparting at least about five turns of twist to said strand to: eiitwine said staple fiber material between and among-the filaments of said strand.

5. The method of claim 4 wherein said filamentary strand before contact with said staple fiber material contains substantially zero turns of twist per inch and said supply of staple fiber material in the form of a loosely assembled and ribboned strand.

6. A method for preparing a slubbed yarn which method comprises bringing a strand containing a plurality of continuous filaments into frictional contact with a dissimilar material at spaced points along its length, said strand having not more than about one turn of twist per inch and said filaments being electrically, substantially non-conducting, permitting said filaments to become separated one from the other at said points as a result of the electrostatic charge imparted from said frictional contact, bringing the filaments of said strand at each of said points into contact with an assemblage of staple fibers, and thereafter imparting at least about five turns of twist per inch to said strand to entwist the assemblages of staple fibers therein.

7. A method according to claim 6 wherein said filamentary strand contains at least about ten filaments, and said points are spaced at random along the length of said strand.

8. Apparatus for forming yarn comprising means adapted to impart an electric charge to a filamentary strand containing a plurality of filaments, means adapted to bring the electrically charged filaments into contact with a source of staple length fibrous material, and means for thereafter twisting the strand whereby said fibers are entwisted between and among said filaments.

9. Apparatus according to claim 8 wherein said first named means comprises a rotatable member adapted to frictionally engage said filamentary strand, and said second named means comprises a drafting frame adapted to have said filamentary strand passed operatively between only the delivery elements thereof.

10. Apparatus for forming a novelty yarn having the general appearances of a spun yarn comprising a rotatable shaft with at least one and not more than two longitudinally extending, protruding blades adapted to contact a multi-filament strand, a drafting frame adapted to receive said strand, following its contact with said blades, between the delivery roll pair and the remaining elements thereof and to thereafter have the strand passed between the rolls of the delivery roll pair, said frame also being adapted to receive and draft a staple fiber strand and pass the same into contact with said multi-filament strand as the latter is passed between the rolls of said delivery roll pair, and means adapted to twist said multi-filament strand following its departure from said drafting frame.

11. Apparatus according to claim 10 provided with means adapted to drive said rotatable shaft in a direction such that said blades oppose the movement of said multifilament strand, and provided with tensioning means adapted to act upon said multi-filament strand before its contact with said blades, whereby said blades act to alternately tension and relax said multi-filament strand as it enters said drafting frame.

12. Apparatus for forming a slubbed yarn comprising a rotatable shaft with a single longitudinally extending, protruding blade adapted to contact a multi-filament yarn end, a drafting frame with the delivery rolls geared independently of the remaining elements of said frame, said delivery rolls being adapted to receive said yarn end following contact with said blade and said remaining ele ments being adapted to receive and draft a staple fiber strand and feed the same into contact with said multi-filament yarn end as it passes between said delivery rolls, means adapted to twist said multi-filament yarn end as it departs said delivery rolls, means to continuously drive said rotatable shaft and said delivery rolls, and means to intermittently drive said remaining elements of said drafting frame.

13. Apparatus according to claim 12 including a shield 14 adapted to retain said multi-tilament yarn out of contact with said blade and means for removing said shield to an inactive position immediately prior to each period of operation of said remaining elements of said drafting frame and returning said shield to an operative position on the termination of each period of operation of said remaining elements.

14. A method for preparing a novelty yarn which comprises spacially separating the individual filaments of a filamentary strand containing a plurality of continuous filaments, bringing the separated filaments together with a drafted ribbon of staple fiber material, and thereafter twisting the strand to entwine the fibrous material between and among said filaments.

15. A method according to claim 14 wherein said filaments and said staple fiber material are brought together by placing the spacially separated continuous filaments in superimposed relationship with said ribbon of staple fiber material and thereafter pressing said filaments and staple fiber material together before twisting.

16. A method of preparing a composite yarn containing continuous filaments and having staple fiber material substantially evenly distributed along the length of the yarn, said method comprising spacially separating the individual filaments in a portion of a running length of filamentary yarn containing a plurality of continuous filaments, bringing the separated filaments together with a drafted ribbon of staple fiber material, supplied at a rate substantially equal to the rate of movement of said filamentary yarn, and thereafter twisting the resulting mixture of staple fiber and filamentary material to entwine the staple fiber material between and among the filaments.

17. A method according to claim 16 wherein the individual filaments of said filament yarn are separated by imparting to the filaments an electric charge so that they become separated from each other as a result of mutual repulsion.

18. A method according to claim 17 wherein said electric charge is imparted by bringing the continuous filaments into frictional contact with a dissimilar material.

19. Apparatus for producing a novelty yarn comprising means for spacially separating the filaments of a continuous filamentary strand, means for supplying a drafted ribbon of staple fiber material, means for bringing the ribbon of staple fiber material together with the separated filaments of said filamentary strand, and means for thereafter twisting the filamentary strand to thereby entwine the staple fibers between and among the filaments.

20. Apparatus according to claim 19 wherein said penultimate means comprises means for bringing said spacially separated continuous filaments into superimposed relationship with said drafted ribbon of staple fiber material and means for thereafter pressing said separated filaments and said ribbon of staple fiber material together.

21. Apparatus according to claim 20 wherein said means for pressing said separated filaments and said ribbon of staple fiber material comprises a pair of rolls between which said filaments and staple fiber material are passed.

22. Apparatus for producing a composite yarn continuous filaments and having staple fiber material substantially evenly distributed along the length of the yarn, said apparatus comprising means for spacially separating the continuous filaments of a filamentary strand at one point in a running length of material, means for supplying a drafted ribbon of staple fiber material at a rate substantially equal to the rate of movement of said filamentary strand, means for bringing the ribbon of staple fiber ma terial together with the separated filaments of said filamentary strand, and means for thereafter twisting the re sulting mixture of staple fiber and filamentary material to entwine the staple fiber material between and among the filaments.

23. Apparatus according to claim 22 wherein said first named means comprises means for imparting an electric 2,623,346 Lohfertzet a1. Dec. 30, 1952 ments by rubbing fritional contact threwith. 

